Air duct support

ABSTRACT

An air duct support for supporting air ducts and similar pipes without constricting airflow through the pipes. The support has an arcuate main body portion for receiving a portion of the conduit therein and an upright support attached to a bottom of the top portion and supporting the conduit at an elevated position in relation to a base surface. The support member may be a unitary body or telescopically extendable member. The top portion rotates 360 degrees in relation to the support member to accommodate any direction of extension of the conduit. A collar plate or a flexible strap may be positioned about an unsecured portion of the conduit to prevent displacement of the conduit in relation to the main body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of my co-pending applicationSer. No. 10/797,896 filed on Mar. 10, 2004, entitled “Duct Holder,” thefull disclosure of which is incorporated by reference herein, andpriority of which is hereby claimed.

BACKGROUND OF THE INVENTION

The present invention relates to conduit supports and, moreparticularly, to a support or holder for supporting hollow conduits,such as air, heating ducts or pipes between adjacent joists of abuilding structure.

Conventionally, heating, cooling, ventilating and air conditioningsystems (HVAC systems) in buildings use pipes, tubes, flexible ducts andother tubular bodies for conveying the air within the building. Thetubular conduits are supported between floor or ceiling joists andnormally secured in a suspended position by nylon straps or metalhangers that are placed between the joists. One problem withconventional duct supports is that the nylon straps or metal bracketshave to be secured to a rafter, which in some cases is located at arelatively high level above a base surface, or floor of an attic. Toreach the rafter, the worker has to climb a ladder or construct aspecial platform high enough to give access to the rafter. Naturally,such method of suspending the tubular conduits takes time and increasesthe cost of the labor involved in the construction of the building.

Another problem with the use of flexible straps is that they tend toconstrict the airflow within a flexible duct. When the strap is tied tothe rafter, it is estimated that about 25% of airflow may be lost due tothe duct constriction. Still another problem associated with suspendingthe air ducts is that a condensate tends to form in the portion of theair duct that sagged between adjacent straps. The accumulated moisturedrips into the insulation, where it can cause damage or facilitatedevelopment of mold and mildew around the duct.

The present invention contemplates elimination of drawbacks associatedwith conventional methods and provision of a duct support that cansupport the ducts or other tubular conduits from above or below theconduit without constricting the flow of gas or fluid through theconduit.

SUMMARY OF THE INVENTION

It is therefore, an object of the present invention to provide a ductsupport that can be used in place of conventional conduit supports in abuilding.

It is another object of the present invention to provide a duct supportparticularly adapted for use with air circulation systems wherein theconduits have to be supported at certain intervals along their lengths.

It is a further object of the present invention to provide an air ductsupport that can be secured to either a joist or rafter and effectivelysupport the air duct without constricting the air flow through the airduct.

These and other objects of the present invention are achieved through aprovision of a support device that allows the conduit to be elevatedabove a base surface, such as the attic floor, without constricting theair flow passing through the conduit. The support device has an arcuatemain body and an upright support member, to which the main body isengaged in free rotational relationship. The main body defines an openchannel for receiving a portion of a conduit therein. The channel issized and shaped to accommodate different shape and diameter conduit,such as for instance air ducts. The upright support can be formed as anupright planar member or with a pair of spaced legs and allowpositioning of the conduit at a desired height above a base surface.

To prevent displacement of the conduit, especially if the support deviceis mounted to a rafter and suspends the main body below the supportmember, is provided with a collar plate or a strap that wraps about anunsupported portion of the air duct. The device can be also secured tojoists, allowing the main body to be oriented above the support member.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will not be made to the drawings, wherein like parts aredesignated by like numerals, and wherein FIG. 1 is a perspective view ofan air duct support in accordance with the first embodiment of presentinvention.

FIG. 2 is a front view of the duct holder of the first embodiment of thepresent invention.

FIG. 3 is a top view of the duct support of the first embodiment of thepresent invention.

FIG. 4 is the bottom view of the duct holder of the first embodiment ofthe present invention.

FIG. 5 is side view of the duct holder of the first embodiment of thepresent invention.

FIG. 6 is a perspective view of an air duct support in accordance withthe second embodiment of present invention.

FIG. 7 is a front view of the duct holder of the second embodiment ofthe present invention.

FIG. 8 is a top view of the duct support of the second embodiment of thepresent invention.

FIG. 9 is the bottom view of the duct holder of the second embodiment ofthe present invention.

FIG. 10 is side view of the duct holder of the second embodiment of thepresent invention.

FIG. 11 is a perspective view of an optional upright support extensionmember for use with the air duct support of the first embodiment of thepresent invention.

FIG. 12 is a front view of the optional upright support extension memberof FIG. 11.

FIG. 13 is a top view of a collar plate member for use when using arafter installation method.

FIG. 14 is a side view of the collar plate member of FIG. 13.

FIG. 15 is an end view of the collar plate member of FIGS. 13 and 14.

FIG. 16 is a perspective view of a supporting strap for use with the airduct support of the present invention.

FIG. 17 is a detail perspective view of a hook used in the supportingstrap.

FIG. 18 is a detail top view of the hook used in the supporting strap.

FIG. 19 is a detail side view of the hook used in the supporting strap.

FIG. 20 is a side view of the supporting strap.

FIG. 21 is a bottom view of the supporting strap.

FIG. 22 is a top view of the supporting strap.

FIG. 23 is a perspective view illustrating position of the supportingstrap on the arcuate position in the first embodiment of the presentinvention.

FIG. 24 is a front view of the air support unit of the first embodimentof the present invention, in use with the supporting strap.

FIG. 25 is a side view of the air duct support unit of the firstembodiment of the present invention, used with the supporting strap.

FIG. 26 is a front view of the air duct support unit of the secondembodiment of the present invention, used with the supporting strap.

FIG. 27 is a side view of the air duct support unit of the secondembodiment of the present invention, used with the supporting strap.

FIGS. 28 a through 28 f are schematic views illustrating a series ofsteps in preparing the air duct support of the instant invention forinstallation.

FIG. 29 is a schematic view illustrating securing of the optionalupright support member.

FIG. 30 is a schematic view illustrating free rotation capability of thearcuate support member in relation to the upright support member.

FIGS. 31 a and 32 b are schematic views illustrating preparation of thecollar plate member for installation.

FIGS. 32 a through 32 c schematically illustrate a series of steps insecuring the collar plate member to the arcuate support member.

FIG. 33 is a schematic view illustrating a plurality of air duct supportunits of the present invention secured to a rafter.

FIG. 34 is a schematic view illustrating a plurality of air duct supportunits of the present invention secured to a joist.

FIG. 35 is a detail view illustrating engagement of the upright supportmember with the securing plate.

DETAIL DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now to the drawings in more detail, numeral 10 designates theair duct support unit in accordance with the first embodiment of thepresent invention. The air duct support 10 comprises a main body member12 and an upright support member 14. The main body 12 has a generallyarcuate body defining a generally C-shaped channel 16 for receiving atubular conduit, such as an air duct 11 therethrough. The main body 12has a bottom surface 18 and opposing ends 15 and 17. The main body 12has a generally C-shaped cross-section so as to accommodate an air ductand extend somewhat along the sides of the conduit, as can be seen inFIG. 28. A rivet 36 secures the main body 12 to the upright supportmember 14, allowing the main body 12 to freely rotate in relation to theupright support 14.

The main body 12 is preferably formed of relatively rigid durablenon-corrosive material, such as polypropylene, aluminum and othercomparable material. The size and shape of the channel 16 formed by themain body 12 varies, depending on the exterior configuration of the ductto be supported by the support unit 10.

A plurality of elongated slots 20 is cut in the main body 12. The slots20 extend along a first edge 21 and a second edge 23 of the main body 12in parallel rows. The slots are spaced substantially equidistantly fromeach other along the length of the edges 21 and 23. A plurality ofopenings 27 is formed in the main body 27; the openings 27 are locatedcentrally between the rows of the slots 20 and are spaced substantiallyequidistantly along the curvature of the main body 12.

The support member 14 is formed from a strong non-corrosive materialcapable of withstanding the weight of a section of the conduit, such asan air duct, resting within the channel 16 of the main body 12. Thesupport member 14 has a generally U-shaped cross-section having acentral wall 22 and a pair of parallel side walls 24 and 26, which areoriented substantially perpendicularly to the central wall 22. Aplurality of spaced-apart openings 28 are formed along the length of thecentral wall 22, extending from the lower portion 30 to the upperportion 32 of the support member 14.

The support member 14 is formed as a unitary body. A pair of cuts 36, 38is made through the walls 24, 26 in the upper portion 32 (FIG. 35). Anattachment bridge 40 is formed by the uppermost part of the supportmember 14. The attachment bridge 40 comprises a central portion 42,which has the same width as the central wall 22, and a pair of side tabs34, 36, which have the same widths as the side walls 24, 26,respectively.

When the attachment bridge 40 is prepared for securing to the main body12, the bridge 40 is bent at 90 degrees in relation to the central wall22. A central opening 48 made in the attachment bridge 40 receives therivet 36, allowing the main body 12 to freely rotate in relation to theupright support 14. An opening 50 is formed in a side tab 44, and asimilar opening 52 is formed in the side tab 46.

When preparing the support 10 for installation, first moves the mainbody 12 to orient the main body 12 above the support 14 (FIGS. 28 a-28c). The main body 12 may be pivotally or hingedly attached to thesupport member 14, as shown in FIGS. 28 a-28 c. The user then bends downthe bridge 40 and then the side tabs 44 and/or 46 (FIGS. 28 d and 28 e)at 90 degrees, so that the side tabs 44, 46 extend in a substantiallyparallel relationship to the side walls 24, 26, respectively. The rivet36 is inserted through the opening made in the main body 12 and throughthe opening 48.

An opening 54 is made in the wall 24 and a similar opening 56 is made inthe wall 26. A user aligns the opening 50 with the opening 54 in thewall 24, and/or aligns the opening 52 with the opening 56 in the wall26. A user then inserts a retaining device, such as for instance a screw58 (FIG. 28f) through the aligned openings 52, 56. An optional secondretaining device may be inserted through the openings 50, 54. Thesupport 14 is thereby made more stable and rigid.

If necessary, an optional support extension member 60 can be added toextend the height of the upright member 14. The extension member 60 hasthe same U-shaped configuration as the support member 14, but smaller insize, so that the extension member 60 fits within the channel defined bythe central wall 22 and the side walls 24, 26. As shown in detail inFIGS. 11 and 12, the extension member 60 has a central wall 62 and apair of opposing parallel side walls 64, 66 (FIGS. 11 and 12).

The central wall 62 is provided with a plurality of spaced openings 68that are aligned in a manner similar to the openings 28 in the centralwall 22. When the height extension of the upright support 14 is desired,the extension member 60 is fitted in the channel formed by the centralwall 22 and the side walls 24, 26 of the support 14 (FIG. 29), and aretaining device, a screw, bolt, etc., is inserted through the alignedopenings 28, 68.

Turning now to FIG. 13-15, a collar plate 70 for use with the air ductsupport device of the present can be seen in more detail. The collarplate 70 comprises a planar body having a generally rectangularconfiguration with opposing parallel edges 72 and 74. Edges 76, 78extend perpendicularly to the edges 72, 74. An elongated slot 80 isformed adjacent the edge 72, and an elongated slot 82 is formed adjacentthe edge 74. The slots 80, 82 are adapted to receive a hook of thesupporting strap, as will be explained in more detail hereinafter.

A pair of opposing notches 84, 86 is formed in the edge 76, 78,respectively adjacent the edge 72, and a similar pair of opposingnotches 88, 90 is formed in the edges 76, 78 adjacent the edge 74. Thenotches 84, 86, 88, and 90 allow the user to form side tabs on thecollar plate 70 for engagement with the main body 12. A plurality ofspaced notches 92 is formed along the edge 76 between the notches 84 and88. A plurality of opposing notches 94 is formed in the edge 78 betweenthe notches 86, 90.

Turning now to FIGS. 31 a and 31 b, a process of preparing the collar 70for use is shown in more detail. The user bends the edges 76 and 78 toform side tabs 96, 98 and 100, 102, as shown by arrows in FIGS. 31 a and31 b. After a conduit 11 is positioned in the channel 16, the userinserts the tabs 96, 98 in opposing slots 20 adjacent an end 15 of themain body 12. This step is schematically illustrated in FIG. 32 a. Theuser then brings the collar 70 around the conduit 11 and secures thetabs 100, 102 in the opposing slots 20 near the end 17 of the main body12.

Should the collar 70 be too long, the user follows the stepsschematically illustrated in FIGS. 32 b and 32 c: the user cuts thecollar 70 along an imaginary line extending between the notches 92, 94to conform the length of the collar 70 to the outside dimensions of theconduit 11. The excess length of the collar 70 is discarded, new sidetabs 100, 102 are formed as described above, by bending along the notchlines 92, 94, and the new tabs are inserted in the notches 20 adjacentthe end 17.

The collar plate can be formed from a variety of materials, such as thinaluminum plate, thin steel plate and the like. The preferred materialcan be bended without breaking, is non-corrosive and strong enough tosupport the weight of the air duct in applications where the main body12 is below the support member 14, such as when the device 10 is securedto a rafter (FIG. 33).

Some tests performed with the prototype of the present invention showedthat the conduit 11 can vibrate and “rattle” when a strong air flowpasses through the duct 11. To cure the problem, the instant inventionprovides for the use of a flexible strap 110, which is wrapped aroundthe exposed portion of the conduit positioned in the channel 16. Thestrap 110 is shown is detail in FIGS. 16-22. The strap 110 comprises anelongated flexible body 112 having an inner surface 114, an outersurface 116, and opposing ends 118, 120. The flexible body 112 may bemade from a stretchable, resilient material.

The strap end 118 is folded over to form an open fold 122, and the strapend 120 is folded over to form an open fold 124. A hook member 126 issecured in the fold 122, and a hook member 128 is positioned in the fold124. The hook members 126 and 128 are identical; both have a hookportion 130 and an attachment part 132, which is configured as arectangular frame with an opening 134. The strap ends 118, 120 arethreaded through the opening 134 before folding over. The free ends ofthe strap 136, 138 are secured to the main body of the strap 112 bystitching, adhesive or any other suitable means.

In operation, the user engages the hook 130 in one of the openings 27and wraps the strap 110 around the duct 11, as shown in FIGS. 23-25. Theuser then secures the opposite end of the strap to the other side of themain body 12 by engaging the second hook 130 with the opening on theother side of the main body 12. The support device 10 can be used in anupright position, with the main body 12 being above the support member14, as shown in FIG. 34, or suspended from a rafter, as shown in FIG.33.

When suspended from a rafter 140, the main body 12 has the channel 16open downwardly. In this application, the collar plate 70 or the strap110 are preferably used to prevent the conduit 11 from slipping out ofthe main body 12. The support member 14 is secured to the rafter byscrews, nails, or other suitable means. When extended upward from ajoist, the main body 12 is positioned above the support member 14 andthe opening of the channel 16 is oriented upwardly. The conduit 11 restswithin the channel 16 without any assistance from a collar 70 or thestrap 110. Still, the strap 110 may be used to reduce vibration, ifdesired. Where needed, the support units 10 may be used at about 4-5feet intervals.

The second embodiment of the air duct support device of the presentinvention is shown in FIGS. 6-10 and 26-27. The second embodiment isgenerally designated by numeral 150. The air duct support device 150comprises a main body 152 and a support member 154. The main body 152,similarly to the first embodiment, comprises an arcuate body defining anopen channel 156 having an opening between opposing ends 153, 155. Themain body 152 is provided with two parallel rows of spaced elongatednotches 157, 159 and spaced openings 161 made between the rows ofnotches 157, 159. The notches 157, 159 are adapted to receive tabs ofthe collar plate 70, while the openings 161 are adapted to receive hooks130 when the strap 110 is used.

The support member 154, in this embodiment, comprises a pair ofspread-apart legs 162, 164, which are oriented at an angle in relationto a central axis of the main body 152. The legs 162, 164 are connectedby a bridge plate 166, which is secured to the main body 152 by a rivet168. The rivet 168 allows free rotation of the main body 152 in relationto the support legs 162, 164, similar to the rotation of the main body12 in relation to the upright support member 14. In both embodiments,the main body 12, 152 can be oriented to any desired position inrelation to the support members to accommodate extension of the conduit11.

The leg 162 comprises an elongated support plate 163 and a unitaryformed attachment plate 165 extending at an obtuse angle in relation tothe longitudinal axis of the support plate 163. The leg 164 comprises anelongated support plate 167 and a unitary attachment plate 169 securedat an obtuse angle to a longitudinal axis of the support plate 167. Anopening 170 is formed in the attachment plate 165, and an opening 171 isformed in the attachment plate 169. The openings 170, 171 are adaptedfor receiving an attachment means therethrough, such as a screw, bolt,nail and the like, for securing the device 150 to a rafter or a joist.

FIGS. 26 and 27 illustrate position of the conduit 11 in relation to thesupport device 150. As can be seen in the drawings, the conduit 11 restswithin the channel 156 and a strap 110 is wrapped around the exposedportion of the conduit 11. The strap is engaged with the openings 161.

Construction regulations require that flexible or hard metal ducts besupported at defined intervals along their length and that sagging ofthe ducts between the supports not exceed more than 2½ inches. Thepresent invention allows support of the air duct from the bottom withoutconstricting the air flow, as is often the case with nylon straps, byallowing the flexible ducts or hard metal ducts to rest within the mainbody 12 or 152. As a result, the loss of airflow is minimized andgreater efficiency of HVAC systems may be achieved. Additionally, thecollection of moisture under the ducts is eliminated since the ducts aresupported in an elevated position above the floor or insulation.

The main body 12 or 152 is rotatably attached to the respective supportmembers 14, 154 by a rivet 36, 168, respectively, allowing the channel16, 156 to be oriented in any desired direction where the air duct needsto be directed. The 360-degree rotation of the main body 12, 152 inrelation to the support member 14, 154 allows the main body 12, 152 tobe oriented in an infinite number of angles in relation to the centralaxis of the support member 14, 154. As result considerable flexibilityin positioning of the support device 10, 150 on any available structuralmember is achieved.

The projecting ends 15, 17 of the main body 12 and ends 153, 155 of themain body 152 extend at a sufficient distance from the bottom of thechannels 16, 156 and from each other as to not constrict the airflowthrough the air duct 11 supported by the support device 10, 150. Thedevice 10, 150 when properly installed can readily support the weight ofa section of the air duct, be it a flexible air duct or a hard metalconduit.

It will be understood that the particular shapes of the main body 12,152 and the support member 14, 154 are examplary and can be easilymodified depending on the requirements of the job. For instance, themain body 12 may be formed as a three-sided body forming a rectangularchannel for accommodating an air duct or other conduit. The supportmember 14 may have an I-shaped cross-section; it may be a solidrectangle, cylinder and the like.

Many other changes and modifications may be made in the design of thepresent invention without departing from the spirit thereof. I thereforepray that my rights to the present invention be limited only by thescope of the appended claims.

1. A conduit support device, comprising: a main body having opposingends and a bottom defining an open channel, said channel being sized andshaped for receiving a portion of the conduit therein; an uprightsupport member secured to the main body, said upright support memberbeing configured for securing to a structural member; and wherein saidmain body is freely rotatable in relation to the support member.
 2. Thedevice of claim 1, further comprising a collar for wrapping about aportion of conduit outside of the channel, said collar being detachablypositionable on said main body.
 3. The device of claim 1, furthercomprising a supporting strap for wrapping about a portion of conduitoutside of the channel, said supporting strap being detachablypositionable on said main body.
 4. The device of claim 2, wherein saidcollar comprises an elongated plate having at least one securing tabformed on each of opposing ends of the plate.
 5. The device of claim 2,wherein said main body is provided with a plurality of spaced slotsextending along edges of the main body, said slots being configured forreceiving said at least one tab of the collar plate therein.
 6. Thedevice of claim 2, wherein said elongated plate has opposing elongatededges and opposing ends, and wherein a plurality of spaced-apart notchesis formed along said opposing elongated edges to allow forming ofsecuring tabs in a plurality of selected locations along the length ofthe collar plate.
 7. The device of claim 3, wherein said supportingstrap comprises a flexible planar body having opposing ends, and whereina hook-shaped securing member is secured on each of the opposing ends ofthe planar body.
 8. The device of claim 7, wherein said main body isprovided with a plurality of spaced-apart openings located between themain body opposing ends, and wherein each of said hook-shaped securingmembers is sized and shaped to engage within a respective opening. 9.The device of claim 1, wherein said support member comprises anattachment bridge secured to the bottom of the main body, and wherein afreely rotatable element is inserted through respective aligned openingsin the bottom of the main body and in the attachment bridge tofacilitate free rotation of the main body in relation to the supportmember.
 10. The device of claim 1, wherein said support member comprisesan upright member having a generally U-shaped configuration, saidupright member comprising a main wall and a pair of parallel side walls.11. The device of claim 10, wherein a plurality of spaced-apart openingsis formed in the main wall of the support member to allow securing ofthe upright support member at a selected distance from the structuralmember.
 12. The device of claim 11, further comprising an extensionsupport member, said extension support member being sized and shaped tofit between the side walls of the upright support member, said extensionsupport member allowing extension of the distance of securing of theupright support member from the structural member.
 13. The device ofclaim 9, wherein said support member comprises a pair of spread-apartsupporting legs, each of said supporting legs being provided with anattachment plate for detachably securing the support member to thestructural member.
 14. The device of claim 13, wherein the attachmentbridge is unitary connected to free ends of the supporting legs andextends between the free ends of the supporting legs.
 15. The device ofclaim 1, wherein said upright supporting member is secured to thestructural member, with the main body being positioned above thesupporting member.
 16. The device of claim 1, wherein said uprightsupporting member is secured to the structural member, with the mainbody being positioned below the supporting member.
 17. The device ofclaim 1, wherein said main body has a generally arcuate configuration toaccommodate cylindrical conduits positioned therein.
 18. A supportdevice for an air duct conduit, comprising: a generally arcuate mainbody having opposing ends and a bottom defining an open channel, saidchannel being sized and shaped for receiving a portion of the air ductconduit therein; an upright support member secured to the main body,said upright support member being configured for securing to astructural member so as to support the main body and the air ductconduit in an elevated position in relation to a base surface; andwherein said main body is freely rotatable in relation to the supportmember.
 19. The device of claim 18, wherein said upright support membercomprises an attachment bridge, and wherein an opening is formed in thebottom of the main body and an opening is formed in the attachmentbridge, and wherein a free rotating rivet is secured within said openingin the bottom of the main body and in the bridge to facilitate freerotation of the main body in relation to the upright support member. 20.The device of claim 18, further comprising a collar for wrapping about aportion of conduit outside of the channel, said collar being detachablypositionable on said main body, said collar comprising an elongatedplate having at least one securing tab formed on each of opposing endsof the plate.
 21. The device of claim 20, wherein said main body isprovided with a plurality of spaced slots extending along edges of themain body, said slots being configured for receiving said at least onetab of the collar plate therein.
 22. The device of claim 20, whereinsaid elongated plate has opposing elongated edges and opposing ends, andwherein a plurality of spaced-apart notches is formed along saidopposing elongated edges to allow forming of securing tabs in aplurality of selected locations along the length of the collar plate 23.The device of claim 18, further comprising a supporting strap forwrapping about a portion of conduit outside of the channel, saidsupporting strap being detachably positionable on said main body. 24.The device of claim 23, wherein said supporting strap comprises aflexible planar body having opposing ends, and wherein a hook-shapedsecuring member is secured on each of the opposing ends of the planarbody.
 25. The device of claim 24, wherein said main body is providedwith a plurality of spaced-apart openings located between the main bodyopposing ends, and wherein each of said hook-shaped securing members issized and shaped to engage within a respective opening.
 26. The deviceof claim 18, further comprising an extension support member, saidextension support member being sized and shaped to detachably engage theupright support member and allow extension of the distance of securingof the upright support member from the structural member.
 27. The deviceof claim 19, wherein said support member comprises an upright planarmember having a generally U-shaped configuration, and wherein saidbridge is unitary connected to said planar member.
 28. The device ofclaim 19, wherein said support member comprises a pair of spread-apartsupporting legs, each of said supporting legs being provided with anattachment plate for detachably securing the support member to thestructural member, and wherein the attachment bridge is unitaryconnected to free ends of the supporting legs and extends between thefree ends of the supporting legs.